Decorative panel system

ABSTRACT

A panel system may be utilized in a variety of ways to protect or enhance the aesthetic features of an underlying object. The panel system may comprise a panel member, an insert and a base member. The insert is positioned between the panel member and the base member. Then the panel member may be attached to the base member. The panel member may include one or more openings and one or more recesses. The recesses may expose a second surface that results in a multi-tone appearance when a finish is applied to the unaltered first surface and the exposed second surface. The multi-tone appearance combines with the material or surface exposed by the openings in the panel member to create a unique appearance.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of U.S. provisionalapplication Ser. No. 60/585,147, entitled “Decorative Stair RiserScreen,” filed 2 Jul. 2004.

BACKGROUND OF THE INVENTION

The present invention relates to a decorative panel and panel system. Inparticular, it relates to a decorative panel and system that can be usedon a stair riser, among other applications.

SUMMARY OF THE INVENTION

The present invention is directed to a decorative panel and panel systemthat can be used on a stair riser, among other applications. A panelsystem having features of the present invention comprises a panelmember, where the panel member has one or more recesses formed in it,which expose an inner surface. The panel member also has one or moreopenings formed in it. The present invention is also directed to amethod of attaching a panel member to a stair riser using cove molding.The cove molding is attached to a strip of material called a build andan upper tread of a stair to secure the panel member to the existingriser. The present invention is also directed to a method for forming apanel member, where one provides a panel member and then forms one ormore recesses or openings in that panel member. The present invention isalso directed to a method of providing a panel system, where oneprovides one or more panel members that have one or more openings andone or more recesses that expose a second surface. Additionally, onealso provides a staircase that contains stair risers and attaches atleast one of the panel members to at least one of the risers.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a partial exploded perspective view of a panel system.

FIG. 2 is a perspective view of the panel member of FIG. 1.

FIG. 3 is an end view of the panel member of FIG. 1.

FIG. 4 is a top plan view of the panel member of FIG. 1.

FIG. 5 is a top plan view of the insert of FIG. 1.

FIG. 6 is a side view of the insert of FIG. 1.

FIG. 7 is a side view of a fastening component.

FIG. 8 is a top plan view of the fastening component of FIG. 7.

FIG. 9 is a perspective view of a staircase with panel members attachedto existing stair risers.

FIG. 10 is a perspective view of an entryway with panel members attachedto the walls to serve as a border and as a chair rail.

FIG. 11 is a perspective view of a light fixture with panel membersattached to the light fixture to serve as molding.

FIG. 12A is a side view of a method of attaching a panel member to anexisting stair riser utilizing cove molding.

FIG. 12B is an enlarged side view of the panel member, riser, build,cove molding and upper tread of FIG. 12A.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 illustrates one embodiment of a panel system 5, comprising apanel member 10, an insert 30 and a base member 40. The panel member 10has a first surface 12 and an unfinished surface 20. The insert 30 has afront surface 32 and a rear surface 34. The base member has a frontsurface 42. In the embodiment pictured, the panel member 10 ispositioned proximate to the insert 30, such that the unfinished surface20 of the panel member 10 is adjacent to the front surface 32 of theinsert 30. The insert 30 and panel member 10 are then positionedproximate to the base member 40, such that the rear surface 34 of theinsert 30 is adjacent to the front surface 42 of the base member 40.

The panel member 10 as illustrated in FIGS. 1-4, includes an unmodifiedfirst surface 12, a second surface 18 formed by a plurality of recesses14, and a plurality of openings 16, which expose the area or materialbeneath or behind the panel member 10. This embodiment of the panelmember 10 also comprises an unfinished top surface 22 and an unfinishedbottom surface 24. The combination of the unmodified first surface 12,the second surface 18 formed by the recesses 14, and the openings 16,may result in a multi-tone appearance when a finish is applied to thefirst surface 12 and the second surface 18 of the panel member 10. Asused herein, the term “finish” refers to any stain, paint, lacquer,polyurethane, veneer, varnish, enamel, powder coating, acid wash,laminate, ink injection, or any similar coating known to one skilled inthe art. Other finishes will be apparent to those of ordinary skill inthe art. It will also be appreciated that any number of recesses 14and/or openings 16 may be used.

In the present example, the recesses 14 are formed into the panel member10 such that the depth of each recess 14 is less than the thickness ofthe panel member 10. This allows the recess 14 to expose the secondsurface 18, so that said second surface 18 may be seen and the finishmay be applied to it. The depth of the one or more recesses 14 inrelation to the depth of the panel member 10 is illustrated in FIGS. 1and 3; however, it is not necessary that each second surface 18 be atthe same depth. While the present drawings show circular recesses 14, itwill be appreciated that a recess 14 may be any shape.

The openings 16 of the present example are formed into the panel member10 so that they extend completely through the thickness of the panelmember 10. Thus, when the panel member 10 is adjacent to another object,such as either the insert 30 or the base member 40, the openings 16expose the material or area behind or beneath the panel member 10. Thedepth of the one or more openings 16 in relation to the thickness of thepanel member 10 is illustrated in FIGS. 1 and 3. While the presentdrawings show circular openings 16, it will be appreciated that anopening 16 may be any shape.

While the present drawings show the recesses 14 and the openings 16arranged in a diagonal line, it will be appreciated that the recesses 14and the openings 16 may be arranged in any location or pattern in theindividual panel member 10. In one embodiment, the recesses 14 and theopenings 16 are arranged in a pattern or design in order to create anaesthetically pleasing appearance. Additionally, a panel system 5 maycomprise a plurality of panel members 10, which may be attached to oneor more base members, where the recesses 14 and the openings 16 arearranged on each individual panel member 10, such that, when the panelmembers 10 are positioned proximate to each other, the recesses 14 andthe openings 16 may create a collective design.

The first surface 12 and second surface 18 of the panel member 10 of thepresent example are further illustrated in FIG. 4. The varyingcompositions of the first surface 12 and second surface 18 may result inthe finish providing a first tone on said first surface 12 and a secondtone on said second surface 18. The material or area behind or beneaththe panel member 10 exposed by the openings 16 is also illustrated byFIG. 4. Once the finish is applied to the first surface 12 and thesecond surface 18, the combination of the varied appearances of thefirst tone on the first surface 12, the second tone on the secondsurface 18, and the area or material behind or beneath the panel member10 may create a unique multi-tone appearance.

The panel member 10 may be constructed of any type of material. Forinstance, the panel member 10 may be constructed of a material whoseoriginal appearance can be changed by being carved entirely through,embossed, etched, scored, scratched, molded, grooved, routed, die cut orsubject to any other process. As an illustrative version of the panelsystem 5, the panel member 10 may be constructed from medium densityfiber core board, which may have a veneer or skin such as hardwood mapleor oak attached, but this material is also available in an unfinishedform. Other potential materials for the panel member 10 include, but arenot limited to, synthetic or pre-fabricated wood material solid wood,exterior treated wood material, plastic, metal, marble, and anycombination material. As discussed earlier in this specification, thefinish applied to the first surface 12 and second surface 18 may be anystain, paint, lacquer, polyurethane, veneer, varnish, enamel, powdercoating, acid wash, laminate, ink injection, or any other finish knownto one skilled in the art. Alternatively, one could also apply onefinish to the first surface 12 and an alternative finish to the secondsurface 18. As yet another illustrative alternative, one could apply afinish to either the first surface 12 or the second surface 18, creatinga first tone on that surface, and leave the other surface unfinished tocreate a second tone. Still other variations will be apparent to thoseof ordinary skill in the art.

The general shape of the panel member 10, which may be but is notlimited to being rectangular, and the recesses 14 and openings 16 may beformed by any appropriate process. For instance, the process may includecarving entirely through, embossing, etching, scoring, scratching,molding, grooving, routing, die cutting or generally changing theappearance of the first surface 12 and exposing the second surface 18 ofpanel member 10. By way of example only, the manufacturing process mayuse a CNC router. Other possible alternatives include but are notlimited to die cutting, laser cutting, plastic injection molding,plastic color-fill processing, or any combination of these or othermanufacturing processes. Still other processes will be apparent to thoseof ordinary skill in the art.

The panel system 5 may include various parts to enable the otherelements of the panel system 5, such as the panel member 10, to beutilized in a wide variety of manners. The following examples areintended to be illustrative and not limiting at all. As shown in FIG. 1the panel system 5 may include an insert 30 and a base member 40. Thebase member 40 may comprise a variety of objects or materials. Forinstance, the base member 40 may comprise an existing stair riser.Alternatively, the base member 40 may be eliminated, and panel member 10may be used as a riser in an existing staircase without stair risers. Insome jurisdictions, building codes may require risers on new andexisting staircases. Therefore, the panel system 5 may be utilized tosatisfy this requirement. The panel member 10 may be used to retro-fitexisting staircases that already contain risers in the manners justdescribed, or the panel member 10 may be incorporated as a riser duringthe construction of a new staircase.

In another embodiment the base member 40 comprises a piece of cabinetry.Alternatively, the base member 40 may comprise a piece of furniture. Inyet another embodiment the base member 40 comprises an outer surface ofa structure, including but not limited to homes, sheds, and playhousesand the panel member 10 may be aligned with an existing window so as toserve as a window treatment or shutter. In yet another embodiment thebase member 40 comprises an interior wall of a structure, and the panelmember 10 may serve as wainscoting, trim molding, as part of athree-dimensional border, or in a frame or unframed to create a piece ofart. In yet another embodiment, the base member 40 may comprise posts orrails, so that the panel member 10 may be utilized as a partition,including but not limited to being used to create a fence or a screen.FIGS. 9-11 illustrate various potential base members 40 and uses for thepanel system 5. Different designs on the panel members 10 can becombined to create an overall pattern or design. FIG. 9 illustrates oneembodiment where the panel members 10 are attached to existing stairrisers. FIG. 10 illustrates yet another embodiment, where the panelmembers 10 are attached to a wall and utilized as a border and as achair rail. FIG. 11 illustrates a third embodiment, where the panelmembers 10 are attached to a light fixture 120 and serve as moldingaround the light fixture 120. Still other objects that may serve as abase member 40 and other ways to utilize the panel member 10 without abase member 40 will be apparent to those of ordinary skill in the art.

As illustrated in FIG. 1, the panel system 5 comprises an insert 30. Theinsert 30 may comprise a thin sheet of any material or combination ofmaterials of any color, texture or pattern. The insert 30 of the presentexample is positioned proximate to the panel member 10, so that thefront surface 32 of the insert 30 is adjacent to the unfinished surface20 of the panel member 10. The rear surface 34 of the insert 30 ispositioned so that it is adjacent to the front surface 42 of the basemember 40. This may allow the front surface 32 of the insert 30 to beviewed through the openings 16 in the panel member 10. The front surface32 of the insert 30 may have a finish applied to it. One embodiment ofinsert 30 is illustrated in FIG. 5 and FIG. 6. The insert 30 maycomprise a variety of materials, including but not limited to plastic,wood, or metal. The insert 30 may be solid or also have features such asthe openings 16 of panel member 10.

In addition to the panel member 10, the insert 30 and the base member40, the panel system 5 may also comprise a fastening component 50. Oneembodiment of the fastening component 50, referred to as a screw andpost system, is illustrated by FIGS. 7 and 8. The fastening component 50may be utilized to secure the panel member 10 to the base member 40. Ifthe panel system 5 comprises an insert 30, the insert 30 may also besecured to the base member 40 with the fastening component 50. Thepresent embodiment of the fastening component 50 comprises a base 58comprising a front surface 62 and a rear surface 60, a plurality ofbolts 52, a plurality of screw-head covers 53, and a plurality ofmaterial specific screws 54. The plurality of screw-head covers 53 maynumber the same as the plurality of bolts 52. The base 58 may alsocomprise a plurality of screw posts 56, numbering the same as theplurality of bolts 52, and a plurality of screw holes 64, numbering thesame as the plurality of material specific screws 54. The screw holes 64may be beveled to allow for a flush finish with the front surface 62once the material specific screws 54 are inserted in the screw holes 64to secure the base 58 to the base member 40. The material specificscrews 54 may be selected based on the object serving as the base member40 or based on other considerations. In one embodiment, the base member40 may comprise a wooden object; therefore the material specific screws54 may comprise wood screws. Still other fastening components 50 will beapparent to those of ordinary skill in the art.

In the embodiment illustrated in FIGS. 7 and 8, in order to secure thepanel member 10 and the insert 30 to the base member 40, first the base58 of the fastening component 50 may be positioned such that the rearsurface 60 of the base 58 is adjacent to the front surface 42 of thebase member 40. The base 58 may be secured to the base member 40utilizing the material specific screws 54 by inserting the materialspecific screws 54 through the screw holes 64 and into the base member40. The bolts 52 may then be inserted through the screw posts 56 andinto the base member 40. The insert 30 and panel member 10 may then bepositioned so that the front surface 32 of the insert 30 is adjacent tothe unfinished surface 20 of the panel member 10 and the bolts 52 areinserted through openings 16 in the insert 30 and panel member 10. Thescrew head covers 53 may then be screwed onto the bolts 52 to secure thepanel member 10 and the insert 30 to the base member 40.

Another embodiment of a fastening component 50 is illustrated by FIGS.12A and 12B. In this embodiment, the panel member 10 is secured to anexisting stair riser 80 utilizing cove molding 78 and a build 76. Thecove molding 78 comprises a top surface 96 and a rear surface 98. Thebuild 76 may comprise a piece of wood or other material cut to the samelength as the panel member 10. The build 76 comprises a top surface 88,a bottom surface 94, a front surface 90 and a rear surface 92. Theexisting stair riser 80 is positioned between an upper tread 72 and alower tread 74.

These surfaces are illustrated in FIG. 12B, an enlarged view of FIG.12A. The build 76 is positioned such that the top surface 88 of thebuild 76 is adjacent to the bottom surface 84 of the upper tread 72, andthe rear surface 92 of the build 76 is adjacent to the front surface 82of the riser 80. The build 76 is then secured to the riser 80 and theupper tread 72 using nails or any other means of attachment apparent toone skilled in the art. The cove molding 78 is then positioned such thatthe rear surface 98 of the cove molding 78 is positioned adjacent to thefront surface 90 of the build 76 and the top surface 96 of the covemolding 78 is positioned adjacent to the bottom surface 84 of the uppertread 72. The cove molding 78 is then secured to the build 76 and theupper tread 72 using nails or any other means of attachment apparent toone skilled in the art. The panel member 10 is inserted into the gapcreated by the riser 80, the build 76, and the cove molding 78, suchthat the unfinished surface 20 of the panel member 10 is adjacent to thefront surface 82 of the existing stair riser 80 and the front surface 12of the panel member 10 is adjacent to the rear surface 98 of the covemolding 78. The bottom surface 24 of the panel member 10 is positionedadjacent to the top surface 86 of the lower tread 74, and the topsurface 22 of the panel member 10 is positioned adjacent to the bottomsurface 94 of the build 76. Once the panel member 10 is positioned asdescribed above, then it is secured to the riser 82.

Alternative methods of utilizing one or more elements of a panel system5 will be apparent to those of ordinary skill in the art. Thesepotential uses include but are not limited to a series of panel members10 stacked, such that the unfinished surface 20 of one panel member 10is adjacent to the front surface 12 of the second panel member 10. Thesize of the openings 16 in each successive panel member 10 may decrease,which may provide a matte effect. In another embodiment, the panelsystem 5 comprises a plurality of panel members 10 and one or more basemembers 40. The plurality of panel members 10 may be attached to the oneor more base members 40 and positioned, so that when the panel members10 are viewed together the panel members 10 create a unique, collectivedesign and an overall aesthetically pleasing appearance.

Of course, the foregoing examples are merely illustrative, and are notintended to be limiting in any way. Having shown and described variousembodiments and concepts of the invention, further adaptations of themethods and systems described herein can be accomplished by appropriatemodifications by one of ordinary skill in the art without departing fromthe scope of the invention. Several of such potential alternatives,modifications, and variations have been mentioned, and others will beapparent to those skilled in the art in light of the foregoingteachings. Accordingly, the invention is intended to embrace all suchalternatives, modifications and variations as may fall within the spiritand scope of the appended claims and is understood not to be limited tothe details of structure and operation shown and described in thespecification and drawings.

1) A panel system, comprising: a panel member, the panel membercomprising: i) a first surface having one or more recesses formedtherein, wherein each of the one or more recesses provides a secondsurface, and ii) one or more openings. 2) The panel system of claim 1,further comprising a base member, wherein the panel member is positionedproximate to the base member. 3) The panel system of claim 1, whereinone or more finishes are applied to the first surface and second surfaceof the panel member, wherein the one or more finishes provides a firsttone on the first surface and a second tone on the second surface of theone or more recesses. 4) The panel system of claim 2, further comprisingan insert positioned between the panel member and the base member. 5)The panel system of claim 2, wherein the base member comprises a stairriser, wherein the panel member is secured to the stair riser. 6) Thepanel system of claim 1, further comprising a staircase, wherein thepanel member is secured to the staircase to be utilized as a stairriser. 7) The panel system of claim 2, wherein the base member comprisesa piece of cabinetry. 8) The panel system of claim 2, wherein the basemember comprises a wall, wherein the panel member is secured to the wallto be utilized as wainscoting. 9) The panel system of claim 9, whereinthe panel member is secured to the wall to be utilized as trim molding.10) The panel system of claim 2, wherein the base member comprises apiece of furniture. 11) The panel system of claim 2, wherein the basemember comprises an outer surface of a structure and a window, whereinthe panel member is secured to the outer surface of the structure nearthe window. 12) The panel system of claim 1, wherein the panel member isutilized to constitute a fence. 13) The panel system of claim 1, whereinthe panel member is utilized to constitute a screen. 14) The panelsystem of claim 2, further comprising a plurality of panel members andat least one base member, wherein the plurality of panel members areattached to the one or more base members to provide a collective,aesthetically pleasing appearance. 15) The panel system of claim 1,further comprising one or more fastening components. 16) The panelsystem of claim 15, wherein the fastening component comprises a screwand post system. 17) The panel system of claim 15, wherein the fasteningcomponent comprises cove molding. 18) A method for attaching a panelmember to a stair riser utilizing cove molding, the method comprising:a) Installing the cove molding; and b) Positioning the panel memberbetween the cove molding and the stair riser. 19) The panel system ofclaim 1, wherein the panel member comprises at least one of a mediumdensity fiber core board, a synthetic wood material, a pre-fabricatedwood material, a solid wood material, exterior treated wood material,plastic, metal, or marble. 20) The panel system of claim 3, wherein thefinish applied to the first surface is different from the finish appliedto the second surface. 21) The panel system of claim 1, wherein at leastone of the one or more recesses or at least one of the one or moreopenings are formed by a manufacturing process utilizing a CNC Router.22) The panel system of claim 1, wherein at least one of the one or morerecesses or at least one of the one or more openings are formed by a diecutting manufacturing process. 23) The panel system of claim 1, whereinat least one of the one or more recesses or at least one of the one ormore openings are formed by a laser cutting manufacturing process. 24)The panel system of claim 1, wherein at least one of the one or morerecesses or at least one of the one or more openings are formed by aplastic injection molding manufacturing process. 25) The panel system ofclaim 1, wherein at least one of the one or more recesses or at leastone of the one or more openings are formed by a plastic color-fillmanufacturing process. 26) A method for forming a panel member, themethod comprising: a) Providing a panel member; b) Forming one or moreopenings in the panel member; and c) Forming one or more recesses in thepanel member. 27) The method of claim 26, wherein the act of forming atleast one of the one or more openings or at least one of the one or morerecesses comprises use of a CNC router. 28) The method of claim 26,further comprising die cutting at least one of the one or more openingsor at least one of the one or more recesses. 29) The method of claim 26,further comprising laser cutting at least one of the one or moreopenings or at least one of the one or more recesses. 30) The method ofclaim 26, wherein the act of forming at least one of the one or moreopenings or at least one of the one or more comprises plastic injectionmolding. 31) The method of claim 26, wherein the act of forming at leastone of the one or more openings or at least one of the one or morerecesses in the panel member comprises plastic color-fill processing.32) A method for providing a panel system, the method comprising: (a)providing a plurality of panel members, each panel member comprising: i.a first surface having one or more recesses formed therein, wherein eachof the one or more recesses provides a second surface, and ii. one ormore openings; (b) providing a staircase, wherein the staircasecomprises a plurality of risers; and (c) securing a panel member of theplurality of panel members to a riser of the plurality of risers. 33)The method of claim 32, further comprising applying one or more finishesto the panel member.